Machinery and Plant Construction

 

Tapping into growth markets and boosting performance with EFESO

Icon Projekte
>500 projects

worldwide in the past
three years

Icon Einsparungen
>40 years

of industry expertise

Icon Personalbestand
⌀ 5 - 20%

reduction in material costs*

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⌀ 20 - 40%

improvement in OEE*

*Reference values from EFESO customer projects in „Industrial Manufacturing“

Growth opportunities in international markets open up promising prospects for machinery and plant construction companies. In particular, technological innovations and increasing demand from emerging markets are boosting the industry. To expand existing customer segments and develop new business areas, two challenges are proving to be particularly critical to success: 

Firstly, to quickly meet global demand from growth markets with competitive products, countries in Asia, Africa, and South America are investing massively in their industrial infrastructure. A strong local presence with a regional supply chain can pay off long-term through higher order volumes and expansion into other market segments. 

Secondly, to make profitable use of automation and digitalization in the company and for the customer. The objectives: To increase efficiency, reduce costs, and improve product quality. The overarching goal is to develop solutions along the entire value chain from selective initiatives. Main segments are: 

1. Machine tools and automation technology 
Milling, turning, or grinding - machine tools form the core of every industrial production. Modern models work with maximum precision and can be integrated into digital production processes. This network provides real-time data on capacity utilization, maintenance requirements, and quality, enabling users to improve their production processes continuously. For manufacturers, this means shorter set-up times, fewer rejects, and more flexible production that adapts quickly to changing customer requirements – a competitive advantage in global markets.

2. Production facilities and assembly equipment 
Production efficiency depends mainly on the quality and performance of the production facilities and the line equipment. Here, systems with intelligent control technology, adaptive robotics, and advanced sensor technology show how processes in the factory can be made faster, more stable, and more effective. At the same time, digitalization is driving forward the networking of tools with the value stream in the factory, so that, for example, downtimes can be reduced and set-up times optimized. 
But it is also worth looking beyond the line: for example, when companies use digital twins of their machines and tools to plan and simulate production processes - thus determining the best way to implement them.

3. Machinery and systems engineering 
New materials, energy-efficient drives, and digitally networked control systems can be used to develop systems that reliably support even the most complex production processes. This also meets customer demand for individually designed products and solutions. 
Modular systems are playing an increasingly important role here. Supplemented by predictive maintenance, AI-based process optimization, and IoT technologies, optimum capacity utilization and the ability to react quickly to new requirements can be achieved.

Optimize capacity utilization and efficiency. Ensure quality. Shaping the future.

Improving the efficiency and effectiveness of industrial machines and systems

With EFESO, you can identify the levers for innovation, quality, cost awareness, and increased performance along your entire value stream. Our project experience from numerous international collaborations with manufacturers of production machines and assembly equipment combines strategy, technology, and implementation expertise. Together, we achieve measurable results in these and other areas: 

  • Balancing cost pressure: Establishing cost management is an essential prerequisite for profitability, for example, in the cost-oriented design of systems (Cost Value Engineering), procurement of components, and optimization of the value chain; developing into a high-performance organization (Zero Base Organization).
  • Using digitalization as a performance driver: Development and operationalization of digital strategies; support in developing innovative products and services; conception, establishment, and further development of a company-owned Smart Factory"; performance improvement with AI.
  • Ensuring the transfer of expertise: Retaining specialist knowledge within the company and passing it on to new employees quickly and effectively; developing qualification programs for specialists and managers; setting up in-house academies and learning factories.
    Find out more at the EFESO Learning Campus.

Clients

Logo HOERBIGER
Logo HOERBIGER
Logo MR Maschinenfabrik Reinhausen
Logo WEISStechnik
Logo SMP
Logo Netzsch
Logo  EOS
Logo von Ardenne
Logo WashTec

CONTACT

  

Dr. Thomas Troll

Dr. Thomas Troll
Senior Partner

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Sönke Johannsen

Sönke Johannsen
Senior Principal

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CASE STUDIES & INSIGHTS - PRACTICAL EXAMPLES

Close-up einer Maschine
©Nordroden/shutterstock.com

CASE STUDY:

A plant and mechanical engineering company had to ensure its competitiveness. EFESO identified all the adjustment screws for the necessary changes at a production site in Germany and got the turnaround going with a multi-layered restructuring approach.

CASE STUDY:

An automotive supplier improved the transparency of work and organizational processes in a production plant for dashboards. With a "Digital Process Twin" from EFESO, the company reduced the reject rate and made improvement potentials in its value creation networks visible.

VALUE AND COST ENGINEERING

CASE STUDY:

Cost transformation from premium to volume provider. Mass manufacturers who expand their Product portfolio into higher price segments are not uncommon. A premium manufacturer of refrigeration appliances, on the other hand, takes the opposite approach. What seems banal from a technological point of view is an enormous challenge from a cost perspective. EFESO accompanied the company in this demanding transformation project.

CASE STUDY:

A manufacturer of machinery and special machines has already achieved a high level of automation in its production processes. Now the company is setting its sights on further, cross-departmental goals for process automation. Together with EFESO, it is defining fields of application in the operations area in which Robot Process Automation (RPA) tools are to ensure time savings and relieve employees.

CASE STUDY:

A start-up wants to position itself as one of the highest-volume European heat pump manufacturers within only four years. In order to achieve this ambitious goal, EFESO develops a production and material flow planning for the construction of the planned Gigafactory and ensures a fast scalability of the production capacities through a Smart Factory concept.

CASE STUDY:

A mechanical engineering company wants to activate the digital innovation potential at its global locations by switching from SAP R/3 to SAP S/4HANA. Together with EFESO, it revitalized an ERP / MES transformation that had previously been started with another service provider and threatened to lead to a costly dead end.

CASE STUDY:

A manufacturer of road construction machinery aligns its global purchasing organization for growth and profitability. Together with EFESO, it succeeds in redesigning processes, roles, and IT structures, implementing digital tools, and thus sustainably increasing the efficiency of procurement worldwide within just 18 months.

INSIGHT:

Identify bottlenecks, resolve them effectively – and boost results fast.
By optimizing machines and equipment, companies can increase output quickly while achieving long-term cost reductions. A targeted approach that directly impacts competitiveness and performance.

INSIGHT:

EFESO supports companies in the end-to-end realignment of their production network – from ideation to ramp-up. As a one-stop shop, we offer strategic, efficient, and hands-on support for every stage of your factory planning.

INSIGHT:

Learn how to invest in the future sustainably through CapEx optimization. By holistically optimizing long-term investments, companies can improve margins, strengthen cash flow, and drive innovation.

INSIGHT:

Discover how we successfully plan and execute factory projects using a ‘one-stop-shop’ approach, as demonstrated in an EFESO project for a 5 GWh battery cell factory.